Hybrid torque bar

Abstract

A hybrid torque bar for a brake assembly may comprise a base portion, a pin extending from a first end of the base portion, and a rail extending between the first end of the base portion and a second end of the base portion opposite the first end. The base portion may be formed using a first manufacturing process. At least one of the pin or the rail may formed using a second manufacturing process. The second manufacturing process may comprise an additive manufacturing technique.

What is claimed is: 
     
       1. A method of making a hybrid torque bar for a wheel assembly, comprising:
 forming a base portion comprising a first metal alloy using a first manufacturing process; 
 forming a pin extending from a first end of the base portion; 
 forming an attachment flange extending from the base portion; and 
 forming a rail extending between the first end of the base portion and a second end of the base portion opposite the first end, wherein at least one of the attachment flange, the pin, or the rail is formed using a forming method comprising:
 forming an interior portion of the at least one of the attachment flange, the pin, or the rail using a second manufacturing process, the second manufacturing process comprising an additive manufacturing technique, wherein the interior portion comprises the first metal alloy and a first percentage by weight of a wear resistant coating material, the wear resistant coating material being different from the first metal alloy;
 forming a gradient transition over the interior portion using the second manufacturing process, wherein the gradient transition includes an increasing percentage by weight of the wear resistance coating material; and 
 forming a wear resistant coating over the gradient transition using the second manufacturing process, wherein the wear resistant coating comprises a second percentage by weight of the wear resistant coating material, the second percentage by weight being greater than the first percentage by weight, and wherein the wear resistant coating forms an exterior surface of the at least one of the attachment flange, the pin, or the rail. 
 
 
 
     
     
       2. The method of  claim 1 , wherein the first manufacturing process comprises at least one of forging, extrusion, casting, machining, stamping, or subtractive manufacturing. 
     
     
       3. The method of  claim 1 , wherein the wear resistant coating material comprises at least one of a metal carbide, a nickel-based alloy, or a nickel-based super alloy. 
     
     
       4. The method of  claim 1 , further comprising:
 forming the gradient transition on, at least, a portion of a surface of the base portion; and 
 forming the wear resistant coating extending over the gradient transition and the portion of the surface of the base portion. 
 
     
     
       5. The method of  claim 1 , wherein the increasing percentage by weight of the wear resistant coating material in the gradient transition is defined by a smooth function of position along the gradient transition. 
     
     
       6. The method of  claim 5 , wherein the smooth function of position comprises at least one a linear function, a logarithmic function, an exponential function, or a quadratic function.